Systems and methods to enhance intake air flow to a gas turbine engine of a hydraulic fracturing unit

ABSTRACT

Systems and methods to increase intake air flow to a gas turbine engine of a hydraulic fracturing unit when positioned in an enclosure may include providing an intake expansion assembly to enhance intake air flow to the gas turbine engine. The intake expansion assembly may include an intake expansion wall defining a plurality of intake ports positioned to supply intake air to the gas turbine engine. The intake expansion assembly also may include one or more actuators connected to a main housing of the enclosure and the intake expansion assembly. The one or more actuators may be positioned to cause the intake expansion wall to move relative to the main housing between a first position preventing air flow through the plurality of intake ports and a second position providing air flow through the plurality of intake ports to an interior of the enclosure.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/162,022, filed Jan. 29, 2021, titled “SYSTEMS AND METHODS TOENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF A HYDRAULICFRACTURING UNIT”, which is a continuation of U.S. Non-Provisionalapplication Ser. No. 16/946,291, filed Jun. 15, 2020, titled “SYSTEMSAND METHODS TO ENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF AHYDRAULIC FRACTURING UNIT”, now U.S. Pat. No. 10,961,908, issued Mar.30, 2021, which claims the benefit of and priority to U.S. ProvisionalPatent Application No. 62/704,987, filed Jun. 5, 2020, titled “SYSTEMSAND METHODS TO ENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF AHYDRAULIC FRACTURING UNIT”, and hereby is incorporated by reference forall purposes as if presented herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to systems and methods for enhancingintake air flow to a gas turbine engine and, more particularly, tosystems and methods for enhancing intake air flow to a gas turbineengine of a hydraulic fracturing unit.

BACKGROUND

Hydraulic fracturing is an oilfield operation that stimulates productionof hydrocarbons, such that the hydrocarbons may more easily or readilyflow from a subsurface formation to a well. For example, a fracturingsystem may be configured to fracture a formation by pumping a fracturingfluid into a well at high pressure and high flow rates. Some fracturingfluids may take the form of a slurry including water, proppants, and/orother additives, such as thickening agents and/or gels. The slurry maybe forced via one or more pumps into the formation at rates faster thancan be accepted by the existing pores, fractures, faults, or otherspaces within the formation. As a result, pressure builds rapidly to thepoint where the formation may fail and may begin to fracture. Bycontinuing to pump the fracturing fluid into the formation, existingfractures in the formation are caused to expand and extend in directionsfarther away from a well bore, thereby creating flow paths to the wellbore. The proppants may serve to prevent the expanded fractures fromclosing when pumping of the fracturing fluid is ceased or may reduce theextent to which the expanded fractures contract when pumping of thefracturing fluid is ceased. Once the formation is fractured, largequantities of the injected fracturing fluid are allowed to flow out ofthe well, and the production stream of hydrocarbons may be obtained fromthe formation.

Prime movers may be used to supply power to hydraulic fracturing pumpsfor pumping the fracturing fluid into the formation. For example, aplurality of gas turbine engines may each be mechanically connected to acorresponding hydraulic fracturing pump via a transmission and operatedto drive the hydraulic fracturing pump. The gas turbine engine,hydraulic fracturing pump, transmission, and auxiliary componentsassociated with the gas turbine engine, hydraulic fracturing pump, andtransmission may be connected to a common platform or trailer fortransportation and set-up as a hydraulic fracturing unit at the site ofa fracturing operation, which may include up to a dozen or more of suchhydraulic fracturing units operating together to perform the fracturingoperation.

The performance of a gas turbine engine is dependent on the conditionsunder which the gas turbine engine operates. For example, ambient airpressure and temperature are large factors in the output of the gasturbine engine, with low ambient air pressure and high ambienttemperature reducing the maximum output of the gas turbine engine. Lowambient pressure and/or high ambient temperature reduce the density ofair, which reduces the mass flow of the air supplied to the intake ofthe gas turbine engine for combustion, which results in a lower poweroutput. Some environments in which hydraulic fracturing operations occurare prone to low ambient pressure, for example, at higher elevations,and/or higher temperatures, for example, in hot climates. In addition,gas turbine engines are subject to damage by particulates in airsupplied to the intake. Thus, in dusty environments, such as at manywell sites, the air must be filtered before entering the intake of thegas turbine engine. However, filtration may reduce the pressure of airsupplied to the intake, particularly as the filter medium of the filterbecomes obstructed by filtered particulates with use. Reduced poweroutput of the gas turbine engines reduces the pressure and/or flow rateprovided by the corresponding hydraulic fracturing pumps of thehydraulic fracturing units. Thus, the effectiveness of a hydraulicfracturing operation may be compromised by reduced power output of thegas turbine engines of the hydraulic fracturing operation.

Accordingly, Applicant has recognized a need for systems and methodsthat provide improved air flow to the intake of a gas turbine engine forhydraulic fracturing operations. The present disclosure may address oneor more of the above-referenced drawbacks, as well as other possibledrawbacks.

SUMMARY

The present disclosure generally is directed to systems and methods forenhancing air flow to an intake of a gas turbine engine of a hydraulicfracturing unit. For example, in some embodiments, an enclosure for agas turbine engine may increase air flow to a gas turbine engine whenpositioned in the enclosure. The enclosure may include a main housingincluding a main housing wall to connect to a platform to support theenclosure and the gas turbine engine. The main housing wall may includea remote end defining an upper perimeter. The enclosure also may includean intake expansion assembly to enhance intake air flow to the gasturbine engine. The intake expansion assembly may include an intakeexpansion wall including a first end defining an expansion perimeterpositioned to fit inside or outside the upper perimeter of the mainhousing. The intake expansion assembly also may include a second endopposite the first end. The intake expansion wall may define a pluralityof intake ports positioned to supply intake air to the gas turbineengine when positioned in the enclosure. The intake expansion assemblyfurther may include a roof panel connected to the second end of theintake expansion wall and enclosing the second end of the intakeexpansion wall. The enclosure also may include one or more actuatorsconnected to the main housing and the intake expansion assembly andpositioned to cause the intake expansion wall to move relative to themain housing between a first position preventing air flow through theplurality of intake ports and a second position providing air flowthrough the plurality of intake ports to an interior of the enclosure.

According some embodiments, a power assembly to provide power to ahydraulic fracturing unit including a driveshaft to connect to ahydraulic fracturing pump, a transmission to connect to a gas turbineengine for driving the driveshaft and thereby the hydraulic fracturingpump, may include an enclosure to connect to and be supported by aplatform. The power assembly also may include a gas turbine enginepositioned in the enclosure and to be connected to the hydraulicfracturing pump via the transmission and the driveshaft. The enclosuremay include a main housing including a main housing wall to connect to aplatform to support the enclosure and the gas turbine engine. Theenclosure also may include an intake expansion assembly to enhanceintake air flow to the gas turbine engine positioned in the enclosure.The intake expansion assembly may include an intake expansion walldefining a plurality of intake ports positioned to supply intake air tothe gas turbine engine. The enclosure further may include one or moreactuators connected to the main housing and the intake expansionassembly, and positioned to cause the intake expansion wall to moverelative to the main housing between a first position preventing airflow through the plurality of intake ports and a second positionproviding air flow through the plurality of intake ports to an interiorof the enclosure.

According to some embodiments, a method for operating a gas turbineengine positioned in an enclosure including a main housing and an intakeexpansion assembly including a plurality of intake ports to enhance airflow to the gas turbine engine, may include activating one or moreactuators to cause the intake expansion assembly to move relative to themain housing from a first position preventing air flow through theplurality of intake ports to a second position providing air flowthrough the plurality of intake ports to an interior of the enclosure.The method also may include receiving one or more position signals fromone or more sensors configured to generate signals indicative of aposition of the intake expansion assembly relative to the main housing.The method further may include determining, based at least in part onthe one or more position signals, whether the intake expansion assemblyis in the second position. The method still further may includeinitiating operation of the gas turbine engine when the intake expansionassembly is in the second position.

Still other aspects and advantages of these exemplary embodiments andother embodiments, are discussed in detail herein. Moreover, it is to beunderstood that both the foregoing information and the followingdetailed description provide merely illustrative examples of variousaspects and embodiments, and are intended to provide an overview orframework for understanding the nature and character of the claimedaspects and embodiments. Accordingly, these and other objects, alongwith advantages and features of the present invention herein disclosed,will become apparent through reference to the following description andthe accompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the embodiments of the present disclosure, areincorporated in and constitute a part of this specification, illustrateembodiments of the present disclosure, and together with the detaileddescription, serve to explain principles of the embodiments discussedherein. No attempt is made to show structural details of this disclosurein more detail than can be necessary for a fundamental understanding ofthe embodiments discussed herein and the various ways in which they canbe practiced. According to common practice, the various features of thedrawings discussed below are not necessarily drawn to scale. Dimensionsof various features and elements in the drawings can be expanded orreduced to more clearly illustrate embodiments of the disclosure.

FIG. 1 schematically illustrates an example hydraulic fracturing systemincluding a plurality of hydraulic fracturing units, and including apartial side section view of a hydraulic fracturing unit according toembodiments of the disclosure.

FIG. 2A is a perspective view of an example power assembly including anexample gas turbine engine and transmission positioned in an exampleenclosure with the enclosure in a first configuration according to anembodiment of the disclosure.

FIG. 2B is perspective view of the example power assembly shown in FIG.2A in a second configuration according to an embodiment of thedisclosure.

FIG. 3 is a partial side section view of the example power assemblyshown in FIG. 2A in the second configuration according to an embodimentof the disclosure.

FIG. 4 is a perspective view of an example gas turbine engine andtransmission according to an embodiment of the disclosure.

FIG. 5 is a partial side section view of an example roof panel of anintake expansion assembly including an example filter according to anembodiment of the disclosure.

FIG. 6 is a partial side section view of an example actuator connectedto an example main housing wall and an example intake expansion assemblyof an enclosure according to an embodiment of the disclosure.

FIG. 7 is a schematic view of an example hydraulic assembly to controloperation of a plurality of example hydraulic actuators according to anembodiment of the disclosure.

FIG. 8 is a partial side section view of an example intake expansionassembly partially extended from an example main housing according to anembodiment of the disclosure.

FIG. 9 is a schematic top view of an example enclosure including a mainhousing and an intake expansion assembly with a roof panel removed toillustrate an interior of the intake expansion assembly according to anembodiment of the disclosure.

FIG. 10 is an underside schematic view of an example roof panelillustrating an example seal material configuration to seal portions ofthe intake expansion assembly with the roof panel according to anembodiment of the disclosure.

FIG. 11A is a partial side section view of an example sensor andactuator connected to an example main housing wall and an example roofpanel according to an embodiment of the disclosure.

FIG. 11B is a partial side section view of another example sensor andactuator connected to an example main housing wall and an example roofpanel according to an embodiment of the disclosure.

FIG. 12 is a schematic illustration of an example power assemblyarrangement including an example supervisory controller for controllingoperation of an example power assembly according to embodiments of thedisclosure.

FIG. 13 is a block diagram of an example method for operating a gasturbine engine of an example hydraulic fracturing unit according to anembodiment of the disclosure.

DETAILED DESCRIPTION

The drawings like numerals to indicate like parts throughout the severalviews, the following description is provided as an enabling teaching ofexemplary embodiments, and those skilled in the relevant art willrecognize that many changes may be made to the embodiments described. Italso will be apparent that some of the desired benefits of theembodiments described can be obtained by selecting some of the featuresof the embodiments without utilizing other features. Accordingly, thoseskilled in the art will recognize that many modifications andadaptations to the embodiments described are possible and may even bedesirable in certain circumstances. Thus, the following description isprovided as illustrative of the principles of the embodiments and not inlimitation thereof.

The phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. As used herein, theterm “plurality” refers to two or more items or components. The terms“comprising,” “including,” “carrying,” “having,” “containing,” and“involving,” whether in the written description or the claims and thelike, are open-ended terms, i.e., to mean “including but not limitedto,” unless otherwise stated. Thus, the use of such terms is meant toencompass the items listed thereafter, and equivalents thereof, as wellas additional items. The transitional phrases “consisting of” and“consisting essentially of,” are closed or semi-closed transitionalphrases, respectively, with respect to any claims. Use of ordinal termssuch as “first,” “second,” “third,” and the like in the claims to modifya claim element does not by itself connote any priority, precedence, ororder of one claim element over another or the temporal order in whichacts of a method are performed, but are used merely as labels todistinguish one claim element having a certain name from another elementhaving a same name (but for use of the ordinal term) to distinguishclaim elements.

FIG. 1 schematically illustrates an example hydraulic fracturing system10 including a plurality (or fleet) of hydraulic fracturing units 12,and a partial side section view of an example hydraulic fracturing unit12 according to embodiments of the disclosure. The plurality ofhydraulic fracturing units 12 may be configured to pump a fracturingfluid into a well at high pressure and high flow rates, so that asubterranean formation may fail and may begin to fracture in order topromote hydrocarbon production from the well.

In some embodiments, one or more of the hydraulic fracturing units 12may include a hydraulic fracturing pump 14 driven by a gas turbineengine (GTE) 16. For example, in some embodiments, each of the hydraulicfracturing units 12 includes a directly-driven turbine (DDT) hydraulicfracturing pump 14, in which the hydraulic fracturing pump 14 isconnected to one or more GTEs 16 that supply power to the respectivehydraulic fracturing pump 14 for supplying fracturing fluid at highpressure and high flow rates to a formation. For example, the GTE 16 maybe connected to a respective hydraulic fracturing pump 14 via atransmission 18 (e.g., a reduction transmission) connected to a driveshaft 20, which, in turn, is connected to a driveshaft or input flange22 of a respective hydraulic fracturing pump 14 (e.g., a reciprocatinghydraulic fracturing pump). Other types of engine-to-pump arrangementsare contemplated.

In some embodiments, one or more of the GTEs 16 may be a dual-fuel orbi-fuel GTE, for example, capable of being operated using of two or moredifferent types of fuel, such as natural gas and diesel fuel, althoughother types of fuel are contemplated. For example, a dual-fuel orbi-fuel GTE may be capable of being operated using a first type of fuel,a second type of fuel, and/or a combination of the first type of fueland the second type of fuel. For example, the fuel may include gaseousfuels, such as, for example, compressed natural gas (CNG), natural gas,field gas, pipeline gas, methane, propane, butane, and/or liquid fuels,such as, for example, diesel fuel (e.g., #2 diesel), bio-diesel fuel,bio-fuel, alcohol, gasoline, gasohol, aviation fuel, and other fuels aswill be understood by those skilled in the art. Gaseous fuels may besupplied by CNG bulk vessels, a gas compressor, a liquid natural gasvaporizer, line gas, and/or well-gas produced natural gas. Other typesand associated fuel supply sources are contemplated. The one or moreGTEs 16 may be operated to provide horsepower to drive the transmission18 connected to one or more of the hydraulic fracturing pumps 14 tosafely and successfully fracture a formation during a well stimulationproject or fracturing operation.

As will be understood by those skilled in the art, the hydraulicfracturing system 10 may include a plurality of water tanks forsupplying water for a fracturing fluid, one or more chemical tanks forsupplying gels or agents for adding to the fracturing fluid, and aplurality of proppant tanks (e.g., sand tanks) for supplying proppantsfor the fracturing fluid. The hydraulic fracturing system 10 also mayinclude a hydration unit for mixing water from the water tanks and gelsand/or agents from the chemical tank to form a mixture, for example,gelled water. The hydraulic fracturing system 10 further may include ablender, which receives the mixture from the hydration unit andproppants via conveyers from the proppant tanks. The blender may mix themixture and the proppants into a slurry to serve as fracturing fluid forthe hydraulic fracturing system 10. Once combined, the slurry may bedischarged through low-pressure hoses, which convey the slurry into twoor more low-pressure lines in a frac manifold 24, as shown in FIG. 1.Low-pressure lines in the frac manifold 24 may feed the slurry to theplurality of hydraulic fracturing pumps 14 shown in FIG. 1, throughlow-pressure suction hoses.

In the example embodiment shown, each of the plurality hydraulicfracturing units 12 includes a GTE 16. Each of the GTEs 16 suppliespower via the transmission 18 for each of the hydraulic fracturing units12 to operate the hydraulic fracturing pump 14. The hydraulic fracturingpumps 14, driven by the GTEs 16 of corresponding hydraulic fracturingunits 12, discharge the slurry (e.g., the fracturing fluid including thewater, agents, gels, and/or proppants) at high pressure and/or a highflow rates through individual high-pressure discharge lines 26 into twoor more high-pressure flow lines 28, sometimes referred to as“missiles,” on the frac manifold 24. The flow from the high-pressureflow lines 28 is combined at the frac manifold 24, and one or more ofthe high-pressure flow lines 28 provide fluid flow to a manifoldassembly, sometimes referred to as a “goat head.” The manifold assemblydelivers the slurry into a wellhead manifold, sometimes referred to as a“zipper manifold” or a “frac manifold.” The wellhead manifold may beconfigured to selectively divert the slurry to, for example, one or morewell heads via operation of one or more valves. Once the fracturingprocess is ceased or completed, flow returning from the fracturedformation discharges into a flowback manifold, and the returned flow maybe collected in one or more flowback tanks.

In the embodiment shown in FIG. 1, one or more of the components of thehydraulic fracturing system 10 may be configured to be portable, so thatthe hydraulic fracturing system 10 may be transported to a well site,assembled, operated for a relatively short period of time to complete ahydraulic fracturing operation, at least partially disassembled, andtransported to another location of another well site for assembly anduse. In the example shown in FIG.1, each of the hydraulic fracturingpumps 14 and GTEs 16 of a respective hydraulic fracturing unit 12 may beconnected to (e.g., mounted on) a platform 30. In some embodiments, theplatform 30 may be, or include, a trailer (e.g., a flat-bed trailer)including a tongue for connecting to a truck and wheels to facilitatemovement of the trailer, for example, as shown in FIG. 1, and/or a truckbody to which the components of a respective hydraulic fracturing unit12 may be connected. For example, the components may be carried bytrailers and/or incorporated into trucks, so that they may be moreeasily transported between well sites.

As will be understood by those skilled in the art, the hydraulicfracturing system 10 may include a fuel supply assembly for supplyingfuel to each of the hydraulic fracturing units 12, a communicationsassembly enabling communications to and/or among the hydraulicfracturing units 12, and/or an electric power assembly to supplyelectric power to and/or among the hydraulic fracturing units 12. One ormore of such assemblies may be arranged according to a “daisy-chain”arrangement, a “hub-and-spoke” arrangement, a combination “daisy-chain”and “hub-and-spoke” arrangement, and modifications thereof. The fuelsupply assembly may include one or more fuel lines configured to supplyfuel from a fuel source to the plurality of hydraulic fracturing units12.

The communications assembly may include one or more communicationscables connected to each of the hydraulic fracturing units 12 andconfigured to enable data communications between the respectivehydraulic fracturing units 12 and a data center located at a positionremote from the hydraulic fracturing units 12 or among the hydraulicfracturing units 12. For example, a data center communications cable mayprovide a communications link between the data center and one or more ofthe hydraulic fracturing units 12, and one or more of the hydraulicfracturing units 12 may include a communications cable to providecommunications to other hydraulic fracturing units 12 of the hydraulicfracturing system 10. In this example fashion, each of the hydraulicfracturing units 12 may be linked to one another and/or to the datacenter. In some embodiments, the data center may be configured totransmit communications signals and/or receive communications signals,and the communications signals may include data indicative of operationof one or more of the plurality of hydraulic fracturing units 12,including, for example, parameters associated with operation of thehydraulic fracturing pumps 14 and/or the GTEs 16, as well as additionaldata related to other parameters associated with operation and/ortesting of one or more of the hydraulic fracturing units 12.

In some embodiments, the electric power assembly may include one or morepower cables connected to one or more (e.g., each) of the hydraulicfracturing units 12 and configured to convey electric power between thehydraulic fracturing units 12 and a remote electrical power source orone or more additional hydraulic fracturing units 12 of the hydraulicfracturing system 10. The electrical power source may be locatedremotely, such that the electrical power source is not mechanicallyconnected directly to the platform 30 of one or more of the hydraulicfracturing units 12. In some embodiments, the electrical power sourcemay include one or more power generation devices and/or one or morebatteries. For example, the electrical power source may include one ormore gensets (e.g., including an internal combustion engine-drivenelectrical power generator) and/or one or more electric power storagedevices, such as, for example, one or more batteries. In someembodiments, one or more of the hydraulic fracturing units 12 mayinclude one or more gensets, one or more batteries, and/or one or moresolar panels to supply electrical power to the corresponding hydraulicfracturing unit 12 and, in some examples, other hydraulic fracturingunits 12 of the hydraulic fracturing system 10. In some such examples,each of the hydraulic fracturing units 12 may supply and/or generate itsown electrical power, for example, by operation of a generator connectedto the GTE 16 and/or to another source of mechanical power, such asanother gas turbine engine or a reciprocating-piston engine (e.g., adiesel engine) connected to the hydraulic fracturing unit 12. In someembodiments, some, or all, of the hydraulic fracturing units 12 may beelectrically connected to one another, such that electrical power may beshared among at least some, or all, of the hydraulic fracturing units12. Thus, if one or more of the hydraulic fracturing units 12 is unableto generate its own electrical power or is unable to generate asufficient amount of electrical power to meet its operationalrequirements, electrical power from one or more of the remaininghydraulic fracturing units 12 may be used to mitigate or overcome theelectrical power deficit.

As shown in FIG. 1, one or more of the hydraulic fracturing units 12 mayinclude a power assembly 32 including an enclosure 34 to connect to andbe supported by the platform 30 according to embodiments of thedisclosure. In some embodiments, as shown, the GTE 16 of the hydraulicfracturing unit 12 may be positioned in the enclosure 34 and connectedto the hydraulic fracturing pump 14 via the transmission 18 and thedriveshaft 20. As shown in FIG. 1, some embodiments of the enclosure 34may include a main housing 36 including a main housing wall 38 toconnect to the platform 30 supporting the enclosure 34 and the GTE 16.For example, the main housing wall 38 may include a proximal end 40connected to the platform 30 and a remote end 42 defining an upperperimeter 44. In some embodiments, for example as shown in FIGS. 2A and2B, the main housing wall 38 may include four substantially planar wallsections 46 forming a substantially rectangular upper perimeter 44.Upper perimeters 44 having different shapes (e.g., non-rectangularshapes) are contemplated.

As shown in FIG. 1, some embodiments of the enclosure 34 also mayinclude an intake expansion assembly 48 to enhance intake air flow tothe GTE 16. For example, the intake expansion assembly 48 may include anintake expansion wall 50 including a first end 52 defining an expansionperimeter 54 positioned to fit either inside or outside the upperperimeter 44 of the main housing 36. For example, as shown in FIGS. 2A,2B, and 3, the expansion perimeter 54 fits inside the upper perimeter 44of the main housing 36, for example, such that the first end 52 of theintake expansion wall 50 fits within the upper perimeter 44 of the mainhousing 36. The intake expansion wall 50 also may include a second end56 opposite the first end 52. In the example shown, the intake expansionassembly 48 also includes a roof panel 57 connected to the second end 56of the intake expansion wall 50, at least substantially closing anopening formed by the second end 56 of the intake expansion wall 50. Theintake expansion wall 50 also may define a plurality of intake ports 58positioned to supply intake air to the GTE 16 positioned in theenclosure 34. In some embodiments, the intake expansion wall 50 mayinclude four substantially planar intake wall sections 60 forming asubstantially rectangular expansion perimeter 54. Expansion perimeters54 having different shapes (e.g., non-rectangular shapes) arecontemplated.

FIGS. 2A and 2B are perspective views of an example power assembly 32including an example enclosure 34, with the enclosure 34 in a firstconfiguration (FIG. 2A) and a second configuration (FIG. 2B), accordingto an embodiment of the disclosure. FIG. 3 is a partial side sectionview of the example power assembly 32 shown in FIGS. 2A and 2B in thesecond configuration according to an embodiment of the disclosure. Asshown in FIGS. 1, 2A, 2B, and 3, some embodiments of the enclosure 34also may include one or more actuators 62 connected to the main housing38 and the intake expansion assembly 48, and positioned to cause theintake expansion wall 50 move relative to the main housing 38 between afirst position, as shown in FIG. 2A, preventing air flow through theplurality of intake ports 58, and a second position, as shown in FIGS.2B and 3, providing air flow through the plurality of intake ports 58 toan interior 64 of the enclosure 34. For example, in the embodimentshown, the intake expansion wall 50 is positioned with respect to themain housing wall 38, such that activation of the one or more actuators62 causes the intake expansion wall 50 to move between a retractedposition, as shown in FIG. 2A, preventing air flow through the pluralityof intake ports 58, to an extended position, as shown in FIGS. 2B and 3,providing air flow through the plurality of intake ports 58 to theinterior 64 of the enclosure 34.

In some embodiments, the intake expansion assembly 48 may serve toenhance intake air flow to the GTE 16, for example, providing arelatively greater mass flow of air for combustion by the GTE 16. Forexample, the relatively greater mass flow of air may be provided, atleast in part, by increasing the area through which air is drawn intothe intake of the GTE 16. Because the intake expansion assembly 48expands relative to the enclosure in which the GTE 16 is positioned, thearea of the intake ports 58 and/or the number of intake ports 58 may beincreased, resulting in a relatively larger total area for drawing airinto the intake of the GTE 16. This may mitigate or eliminate theeffects of reduced ambient air pressure and/or elevated ambient airtemperature in an environment in which the GTE 16 is operating, such asan environment at a high elevation and/or a warmer climate at whichhydraulic fracturing operation is being performed by the hydraulicfracturing system 10 including the hydraulic fracturing units 12. Insome examples, pressure drop of air entering the intake of the GTE 16due to the air passing through filtration devices may be mitigated oreliminated due to the relatively increased mass flow of air. Inaddition, in some embodiments, the expandable and retractable capabilityof the intake expansion assembly 48 may facilitate transport of thehydraulic fracturing unit 12 between well sites using public highways,while complying with government regulations related to the maximumdimensions of vehicles permitted to travel on public highways.

As shown in FIGS. 2A, 2B, and 3, the main housing 36 may define alongitudinal axis X extending between opposing wall sections 46 locatedat opposite ends of the main housing 36. A first one of the opposingwall sections 46 may include an exhaust duct port 66 through whichexhaust from operation of the GTE 16 passes via an exhaust duct 68 ofthe GTE 16. A second one of the opposing wall sections 46 may include adriveshaft port 70 through which a driveshaft 72 connecting thetransmission 18 to the hydraulic fracturing pump 14 may pass. As shownin FIGS. 1 and 3, some embodiments of the enclosure 34 may include oneor more heat exchangers 73 to cool air in the interior 64 of theenclosure 34. The one or more heat exchangers 73 may include one or morefans and/or one or more air-to-air or fluid-to-air radiators.

As shown in FIGS. 3 and 4, according to some embodiments, the GTE 16includes an intake 74 configured to supply air drawn into the enclosure36 to the GTE 16 for use during combustion. For example, as shown inFIG. 4, the GTE 16 includes two intake ports 76 configured to providethe GTE 16 with air for combustion. The example embodiment of intakeexpansion assembly 48 shown in FIG. 3 includes an expansion base 78connected to the first end 52 of the intake expansion wall 50. As shown,the expansion base 78 may include one or more expansion base intakeports 80 providing intake flow between the one or more expansion baseintake ports 80 and the intake 74 of the GTE 16 when the intakeexpansion wall 50 is in the second position (e.g., in the expandedcondition). In some embodiments, the power assembly 32 may also includeone or more intake ducts 82 connected to the expansion base 78 at theone or more expansion base intake ports 80 and the intake 74 of the GTE16. For example, each of the one or more intake ducts 82 may beconnected at one end to the expansion base intake ports 80 and at asecond end to the intake ports 76 of the intake 74 of the GTE 16 toprovide one or more conduits to supply air to the GTE 16 for combustion.In some embodiments, the one or more intake ducts 82 may be flexible tochange from an at least partially retracted condition when the intakeexpansion assembly 48 is in the first position (e.g., the retractedcondition) to an extended condition when the intake expansion assembly48 moves from the first position to the second position (e.g., theexpanded condition, for example, as shown in FIG. 3).

As shown in FIGS. 2B and 3, some embodiments of the intake expansionassembly 48 may include one or more filters 84 connected to the intakeexpansion wall 50 to filter air entering the enclosure 34 via theplurality of intake ports 58. For example, the one or more filters 84may include a filter frame 86 and a screen mesh 88 retained by thefilter frame 86. In some examples, the screen mesh 88 may have a meshsize 3 with the mesh wire size being at least about 0.047 inches indiameter. In some examples, the screen mesh 88 may be woven,double-crimped, and/or brazed.

In some examples, one of more the intake ports 58 and one or more of thefilters 84 may be provided on three sides of the intake expansion wall50. For example, one of the four intake wall sections 60 may not includeany intake ports 58 or filters 84. In some embodiments, for example, theintake wall section 60 adjacent the main housing wall section 46 thatincludes the exhaust duct port 66 may be devoid of any intake port toprevent exhaust exiting the exhaust duct port 66 from entering theintake 74 of the GTE 16 during operation.

FIG. 5 is a partial side section view of an example roof panel 57 of anintake expansion assembly 48, including an example filter 84 accordingto an embodiment of the disclosure. In the example shown, the roof panel57 may include one or more slots 90 through which the one or morefilters 84 may slide into position to cover a corresponding one or moreof the intake ports 58 in the intake expansion wall 50. In someembodiments, one or more retention rails may be connected to an interiorside of the intake expansion wall 50 to form a retainer frame into whichthe one or more filters 84 may slide and be retained therein. Forexample, the retention rails may include U-channels and/or C-channelsattached to the interior side of the intake expansion wall 50 to providerecesses into which edges of the filter 84 may be received. In someexamples, the retention rails, the retainer frame, and/or the filterframe 86 may be configured to provide a substantially air-tight sealbetween the edges of the filter 84 and edges of the intake ports 58 toprevent particulates from entering the interior 64 of the enclosure 34without passing through the filter 84. For example, the retention rails,the retainer frame, and/or the filter frame 86 may include a sealmaterial, such as a gasket and/or sealant to provide the substantiallyair-tight seal.

As shown in FIG. 5, some embodiments of the filter 84 may also include aretainer bar 92 configured to secure the filter 84 in its installedposition with respect to the intake port 58. For example, the retainerbar 92 may be attached to one edge of the filter 84, for example, to oneedge of the filter frame 86, such that when the filter 84 slides intoposition with respect to the intake port 58, the retainer bar 92 may bepositioned substantially flush with an upper surface of the roof panel57. The retainer bar 92, in some examples, may include a plurality ofholes 94 configured to receive fasteners 96, such as bolts and/orscrews, to secure the retainer bar 92 to the roof panel 57. In someexamples, a seal material 98, such as a gasket and/or sealant may beprovided between the retainer bar 92 and an upper surface of the roofpanel 57 to prevent fluid and/or particulates from entering the intakeexpansion assembly 48 via the slots 90 in the roof panel 90.

In some examples, the intake expansion assembly 48 may also include oneor more second filters positioned in the intake expansion assembly 48between the one or more filters 84 and the intake 74 of the GTE 16. Forexample, the one or more second filters may comprise a second set offilters interior with respect to the filters 84, for example, such thatair entering the intake expansion assembly 48 is subjected to two levelsof filtration prior to entering the intake 74 of the GTE 16. In someexamples, the second set of filters may be positioned relative to thefilters 84 to provide relatively less turbulent flow and/or a relativelylower pressure drop of the air supplied to the intake 74 of the GTE 16.

In some examples, the filtration may be configured to permit entry of upto about 30,000 cubic feet per minute of air having a velocity of about75 feet per second. The filtration, in some examples, may be configuredto remove large particulates that may be harmful to the GTE 16 (e.g., tothe axial compressor section of the GTE 16). Table 1 below providesexamples of percentages of particles of certain sizes that may beremoved for each measurable volume of air entering the intake expansionassembly 48. For example, as shown in Table 1, less than about 6% ofparticulates having a size of about 0.3 micrometers or less may beacceptable, while less than about 0.5% of particulates having a size ofabout 5.0 micrometers may be acceptable. In some examples, thefiltration (e.g., the filters 84 and second filters) may be configuredto remove 99% of water and moisture having a droplet size of about 60micrometers with a salt content of less than about 0.005 parts permillion. In some embodiments, the filters 84 and/or second filters maybe configured such that the pressure drop of air passing through thefilters is less than about two inches of water, for example, from filterinlet to filter outlet.

TABLE 1 Particle Fractional Efficiency Particle Size Percent(micrometers) Retained 0.3 μm 94.0% 0.5 μm 96.0% 1.0 μm 98.8% 5.0 μm99.5% Overall 99.9% Efficiency

FIG. 6 is a partial side section view of an example actuator 62connected to an example main housing wall 38 and an example intakeexpansion assembly 48 of an example enclosure 34 according to anembodiment of the disclosure. As shown in FIG. 6, in some embodiments,the one or more actuators 62 may include one or more linear actuatorsincluding a first end 100 connected to the main housing wall 38 and asecond end 102 connected to the intake expansion assembly 48 andpositioned such that activation of the one or more actuators 62 causesthe intake expansion wall 50 to move between a retracted positionpreventing air flow through the plurality of intake ports 58 to anextended position providing air flow through the plurality of intakeports 58 to the interior 64 of the enclosure 34. For example, a mountingbracket 104 may be connected to an outer surface 106 of the main housingwall 38, and the first end of the actuator 62 may be connected to themounting bracket 104. In some embodiments, the roof panel 57 may includea perimeter edge 108 extending laterally beyond an outer surface 110 ofthe intake expansion wall 50, and the second end 102 of the one or moreactuators 62 may be connected to the perimeter edge 108 of the roofpanel 57. In some examples, the perimeter edge 108 may extend beyond theouter surface 110 in an uninterrupted manner around the periphery of theintake expansion wall 50. In some embodiments, the perimeter edge 108may be discontinuous, for example, extending beyond the outer surface110 only to provide a connection point for the second end 102 of the oneor more actuators 62.

The one or more actuators 62 may include one or more hydraulic linearactuators, one or more pneumatic linear actuators, and/or one or moreelectric linear actuators. In some embodiments, the one or moreactuators 62 may include one or more rotary actuators, for example, oneor more hydraulic rotary actuators, one or more pneumatic rotaryactuators, and/or one of more electric rotary actuators. For example,the one or more rotary actuators may include an actuator base connectedto the main housing 36 or the intake expansion assembly 48 and a rotarymember connected to a linkage (e.g., a rack and/or a crank-rocker)connected to the other of the main housing 36 or the intake expansionassembly 48, for example, such that activation of the one or more rotaryactuators causes the intake expansion wall 50 to move between aretracted position preventing air flow through the plurality of intakeports 58 to an extended position providing air flow through theplurality of intake ports 58 to the interior 64 of the enclosure 34. Insome embodiments, the one or more actuators 62 may include a combinationof linear actuators and rotary actuators. Other types of actuators arecontemplated.

As shown in FIG. 6, some embodiments of the intake expansion assembly 48may include a flexible membrane 112 extending between the main housingwall 38 and the intake expansion wall 50. The flexible membrane 112 maybe configured provide a barrier to prevent air, particulates, and/orfluids from passing between the main housing wall 38 and the intakeexpansion wall 50, regardless of the position of the intake expansionassembly 48 relative to the main housing 36. In some examples, theflexible membrane 112 may be formed from natural and/or syntheticmaterials that are flexible, elastic, fluid-resistant, and/orair-resistant (e.g., a nitrile rubber sheet), for example, to preventparticulates, fluids, and/or air to pass through the flexible membrane112 and/or to maintain a vacuum while the GTE 16 is operating and air isbeing supplied through the intake ports 58 to the intake 74 of the GTE16. As shown, some embodiments of the flexible membrane 112 may beconnected to the main housing wall 38 and/or the intake expansion wall50 to provide a loop in the flexible membrane 112 when the intakeexpansion assembly 48 is in the retracted position, for example, asshown. The loop may reduce the likelihood or prevent the flexiblemembrane 112 from being pinched between the main housing wall 38 and theintake expansion wall 50 during retraction of the intake expansionassembly 48.

In some examples, the flexible membrane 112 may be continuous and extendaround an inner surface 114 of the upper perimeter 44 of the mainhousing wall 38 and the outer surface 110 of the intake expansion wall50 in an uninterrupted manner. For example, a first membrane retainer116 may connect a first end 118 of the flexible membrane 112 to the mainhousing wall 38, and a second membrane retainer 120 may connect a secondend 122 of the flexible membrane 112 to the intake expansion wall 50.The first and second membrane retainers 116 and 120 may include a bar orbars extending with the flexible membrane 112 and providing recessedholes for receiving retaining fasteners (e.g., screws and/or bolts) tosecure the flexible membrane 112 to the main housing wall 38 and theintake expansion wall 50, for example, as shown in FIG. 6.

FIG. 7 is a schematic view of an example hydraulic assembly 124configured to control operation of a plurality of example hydraulicactuators 62 according to an embodiment of the disclosure. As shown inFIG. 7, the example hydraulic assembly 124 includes a hydraulicreservoir 126 containing a supply of hydraulic fluid, and one or morehydraulic pumps 128 configured to draw hydraulic fluid from thehydraulic reservoir 126 and provide pressurized hydraulic fluid via thehydraulic conduits 130 to the components of the hydraulic assembly 124for operation of the hydraulic actuators 62, and to return hydraulicfluid to the hydraulic reservoir 126.

In the example shown, the example hydraulic actuators 62 aredouble-acting hydraulic cylinders connected to the main housing 36 andthe intake expansion assembly 48, for example, as described herein withrespect to FIG. 6. The example hydraulic assembly 124 includes two flowcontrol valves 132 to operate each of the hydraulic actuators 62. Insome examples, the flow control valves 132 operate to allow hydraulicfluid to enter the hydraulic actuators 62 through a check valve at anunrestricted flow rate, but at a restricted flow rate when flowing fromthe hydraulic actuators 62, thereby reducing the speed of operation ofthe hydraulic actuators 62 when the cylinder of the hydraulic actuators62 is retracting, which, in some examples, corresponds to the intakeexpansion assembly 48 retracting. The example hydraulic assembly 124shown also includes a directional control valve 134 including anelectrically-operated solenoid 136 to operate the directional controlvalve 134.

During operation of the example hydraulic assembly 124, which may beconnected to the platform of the hydraulic fracturing unit 12 includingthe GTE 16 and enclosure 34, in a deactivated state, the solenoid 136causes the directional control valve 134 to operate to retract thehydraulic actuators 62, thereby resulting in retraction of the intakeexpansion assembly 48. If a control signal is sent to the solenoid 136to extend the intake expansion assembly 48, a spool in the directionalcontrol valve 134 shifts, diverting flow of hydraulic fluid to extendhydraulic actuators 62, thereby causing the intake expansion assembly 48to extend to its second or extended position. In some examples,hydraulic fluid on the retraction end of the hydraulic cylinders 62flows out of the hydraulic cylinders 62 via the flow control valves 132.The check valve in the flow control valves 132 blocks the flow andforces the fluid to exit the hydraulic actuators 62 through an orificeside of the flow control valves 132, resulting in a restriction in flowthat slows operation of the hydraulic cylinders 62. To retract thehydraulic cylinders 62 and thereby retract the intake expansion assembly48, the control signals to the solenoid may be discontinued and thespool may switch to a deactivated position, causing the intake expansionassembly 48 to retract to its retracted first position.

FIG. 8 is a partial side section view of an example intake expansionassembly 48 partially extended from an example main housing 36 accordingto an embodiment of the disclosure. As shown in FIG. 8, some embodimentsof the enclosure 34 may include one or more fans 138 connected to theintake expansion assembly 48 and configured to draw air into the intakeexpansion assembly 48 for supply to the GTE 16 for combustion. Forexample, the one or more fans 138 may be at least partially enclosed inone or more fan housings 140 and driven by one or more fan motors 142,for example, as shown in FIG. 8. As shown, the one or more fan housings140 may be connected to the intake expansion assembly 48, for example,to the expansion base 78.

In some embodiments, the one or more fans 138 may be axial flow fansand/or centrifugal flow fans, and the one or more fan motors 142 may behydraulic motors and/or electric motors. As shown in FIG. 8, the intakeexpansion assembly 48 may include one or more lines 144 to supply powerand/or control signals to the one or more fans 138. For example, in someembodiments, the one or more fan motors 142 may be hydraulic fan motors,and the one or more lines 144 may include a hydraulic fluid supply line,a hydraulic fluid return line, and a hydraulic fluid line for drainingthe hydraulic motor. In some embodiments, the one or more fan motors 142may be electric fan motors, and the three one or more lines 144 mayinclude electrical lines for supplying electrical power to each of threephases of a three-phase electric motor. The one or more lines 144 may beconfigured to pass through the expansion base 78 via holes 146, whichmay be configured to providing a sealing and/or sliding fit with theexterior surfaces of the lines 144. In some embodiments, the lines 144may be flexible to accommodate retraction and extension of the intakeexpansion assembly 48.

FIG. 9 is a schematic top view of an example enclosure 34 including amain housing 36 and an intake expansion assembly 48 with the roof panel57 removed to illustrate an interior 148 of the intake expansionassembly 48 according to an embodiment of the disclosure. As shown inFIG. 9, the intake expansion assembly 48 includes an intake expansionwall 50 defining an expansion perimeter 54 configured to fit inside theupper perimeter 44 of the main housing wall 38. The intake expansionwall 50 may define a plurality of intake ports 58 providing a flow pathinto the interior 148 of the intake expansion assembly 48. As describedpreviously herein, first filters 84 may be connected to the intakeexpansion wall 50 and positioned to filter air passing through theintake ports 58 and into the interior 148 of the intake expansionassembly 48. In addition, in some embodiments, the intake expansionassembly 48 may include second filters 150 positioned relative to theintake ports 58, such that air passing through the first filters 84 issubjected to further filtration via the second filters 150 prior topassing into the interior 148 of the intake expansion assembly 48.

As shown in FIG. 9, the example intake expansion assembly 148 includesan interior partition 152 generally dividing the interior 148 of theintake expansion assembly 148 into a first portion 154 and a secondportion 156. As shown, the first portion 154 of the interior 148includes a first fan 138A in a first fan housing 140A for drawing airinto the first portion 154 of the interior 148, and the second portion156 of the interior 148 includes a second fan 138B in a second fanhousing 140B for drawing air into the second portion 156 of the interior148. In some examples, as shown in FIG. 9, the intake expansion assembly48 may also include cooling coils 158 positioned downstream of the firstfan 138A and the second fan 138B and configured to cool intake airpulled into the interior 148 of the intake expansion assembly 48 priorto entering the expansion base intake ports 80 positioned downstream ofthe cooling coils 158 and through which the intake air is supplied tothe intake 74 of the GTE 16, for example, as previously describedherein. In some examples, cooling the intake air supplied to the intake74 of the GTE 16 may result in increasing the density of the intake air,thereby potentially increasing the power output of the GTE 16.

FIG. 10 is an underside schematic view of an example roof panel 57illustrating an example seal material configuration 160 to seal portionsof the intake expansion assembly 48 with the roof panel 57 according toan embodiment of the disclosure. As shown in FIG. 10, the underside ofthe roof panel 57 may include a plurality of seal material segments 162configured to provide a substantially air-tight seal with the remainderof the intake expansion assembly 48 when the roof panel 57 is secured tothe remainder of the intake expansion assembly 48. For example, the sealmaterial segments 162 may include perimeter seal segments 164 positionedto provide a seal with the second end 56 of the intake expansion wall50, cooling coil seal segments 166 positioned to provide a seal withedges of the cooling coils 158, fan seal segments 168 positioned toprovide a seal with edges of the first and second fan housings 140A and140B, a partition seal segment 170 positioned to provide a seal with anedge of the interior partition 152, and/or filter seal segments 172positioned to provide a seal with edges of interior walls supporting thefirst filters 84 and/or second filters 150. Once the roof panel 57 issecured to the second end 56 of the intake expansion wall 50, the sealmaterial segments 162 may provide an air-tight seal with theabove-mentioned components of the intake expansion assembly 48 to ensurethat air entering the intake 74 of the GTE 16 has been sufficientlyfiltered. In some examples, a plurality of mounting holes may beprovided in the roof panel 57 through one or more of the seal materialsegments 162, such that the seal material segments 162 seal the mountingholes when fasteners, such as screws and/or bolts, are passed throughthe mounting holes to secure the roof panel 57 to the remainder of theintake expansion assembly 48.

FIGS. 11A and 11B are partial side section views of example sensors 174and actuators 62 connected to an example main housing wall 38 and anexample roof panel 57 according to embodiments of the disclosure. Asshown, the intake expansion assembly 48 may include one or more sensors174 connected to the main housing 36 and/or the intake expansionassembly 48, and positioned to generate one or more position signalsindicative of a position of the intake expansion assembly 48 relative tothe main housing 36. For example, in the example embodiment shown inFIG. 11A, the sensor 174 includes a proximity sensor including atransceiver 176 attached to the remote end 42 on the main housing wall38 and configured to send a signal toward a reflector 178 attached tothe perimeter edge 108 of the roof panel 57 of the intake expansionassembly 48. In some embodiments, the transceiver 176 may be configuredto generate and receive signals reflected by the reflector 178, whichmay be used to determine the distance between the remote end 42 of mainhousing wall 38 and the perimeter edge 108 of the roof panel 57, whichmay be used to determine whether the intake expansion assembly 48 isretracted or extended.

As shown in FIG. 11B, in some embodiments, the example sensor 174includes a potentiometer including a cylinder 180 attached adjacent theremote end 42 of the main housing wall 38 and a rod 182 received in thecylinder 180 and attached the perimeter edge 108 of the roof panel 57 ofthe intake expansion assembly 48. In some embodiments, potentiometer mayinclude a transducer configured to generate signals indicative of thedistance between the remote end 42 of main housing wall 38 and theperimeter edge 108 of the roof panel 57 based at least in part on theposition of the rod 182 relative to the cylinder 180, which may be usedto determine whether the intake expansion assembly 48 is retracted orextended.

FIG. 12 is a schematic illustration of an example power assembly controlsystem 184 for controlling operation of an example power assembly 32according to embodiments of the disclosure. As shown in FIG. 12, theexample power assembly control system 184 may include a supervisorycontroller 186 in communication with the one or more actuators 62 andconfigured to cause the one or more actuators 62 to activate and causemovement of the intake expansion assembly 48 between the first retractedposition and the second extended position. For example, the powerassembly control system 184 may include an actuator controller 188configured to receive one or more signals from the supervisorycontroller 186 to activate the one or more actuators 62. For example,the actuator controller 188 may cause the hydraulic assembly 124 (FIG.7) to operate and cause activation of the one or more actuators 62, forexample, as previously explained herein. In some examples, the actuators62 may be electric actuators, and the actuator controller 188 may beconfigured to cause operation of an electrical assembly to activate theelectric actuators.

As shown in FIG. 12, in some embodiments, the one or more sensors 174may be in communication with the supervisory controller 186 and maygenerate one or more position signals indicative of a position of theintake expansion assembly 48 relative to the main housing 36, forexample, as described previously herein. The power assembly controlsystem 184 may be configured to receive the one or more position signalsand either prevent or allow operation of the GTE 16 and/or the one ormore fans 138, for example, based at least in part on whether the one ormore position signals indicate the intake expansion assembly 48 is inthe second extended position. For example, if the supervisory controller186 determines that the intake expansion assembly 48 is not in thesecond extended position, the supervisory controller 186 may prevent theone or more fans 138 from being activated and/or prevent the GTE 16 fromstarting operation.

For example, as shown in FIG. 12, the power assembly control system 184may include a fan controller 190 in communication with the supervisorycontroller 186 and configured to receive signals from the supervisorycontroller 186 to activate the one or more fan motors 142 of the one ormore fans 138, for example, based at least in part on whether the intakeexpansion assembly 48 is in the second extended position. If not, thesupervisory controller 186 may not send activation signals to the one ormore fan motors 142, preventing operation of the one or more fans 138,unless the intake expansion assembly 48 is in the second extendedposition.

As shown in FIG. 12, in some embodiments, the power assembly controlsystem 184 may include a turbine controller 192 in communication withthe supervisory controller 186 and configured to receive signals fromthe supervisory controller 186 to activate operation of the GTE 16, forexample, initiating a start-up sequence for the GTE 16, based at leastin part on whether the intake expansion assembly 48 is in the secondextended position. If not, the supervisory controller 186 may not sendactivation signals to the turbine controller 192, preventing operationof the GTE 16, unless the intake expansion assembly 48 is in the secondextended position.

FIG. 13 is a block diagram of an example method 1300 for operating a gasturbine engine of an example hydraulic fracturing unit according to anembodiment of the disclosure, illustrated as a collection of blocks in alogical flow graph, which represent a sequence of operations. In thecontext of software, the blocks represent computer-executableinstructions stored on one or more computer-readable storage media that,when executed by one or more processors, perform the recited operations.Generally, computer-executable instructions include routines, programs,objects, components, data structures, and the like that performparticular functions or implement particular data types. The order inwhich the operations are described is not intended to be construed as alimitation, and any number of the described blocks can be combined inany order and/or in parallel to implement the methods.

FIG. 13 is a flow diagram of an embodiment of a method 1300 foroperating a gas turbine engine of an example hydraulic fracturing unit,for example, associated with a hydraulic fracturing system, according toan embodiment of the disclosure.

The example method 1300, at 1302, may include activating a supervisorycontroller configured to control operation of one or more components ofa hydraulic fracturing unit. In some embodiments, this may includeinitiating operation of a supervisory controller configured to controloperation of a hydraulic fracturing pump, a gas turbine engine, one ormore fans, one or more actuators, and/or auxiliary systems of thehydraulic fracturing unit, including, for example, a hydraulic assembly,an electric assembly, and/or a pneumatic assembly.

At 1304, the example method 1300 further may include selecting one ormore hydraulic fracturing unit operating parameters associated withoperating the hydraulic featuring unit. For example, the hydraulicfracturing unit may include an operator interface, which may be used byan operator to select operating parameters, which may include parametersrelated to operation of a hydraulic fracturing pump of the hydraulicfracturing unit, such as pump speed, pump output including pump pressureand/or flow rate of a fracturing fluid pumped by the hydraulicfracturing pump. In some examples, operating parameters may relate tooperation of the gas turbine engine, such as engine speed, power output,fuel source, and/or type(s) of fuel, as will be understood by thoseskilled in the art.

At 1306, the example method 1300 also may include activating a hydraulicfracturing unit auxiliary power source. For example, the hydraulicfracturing unit may include a hydraulic assembly configured to operateone or more hydraulic components used to facilitate operation of thehydraulic fracturing unit, for example, as discussed herein. In someembodiments, this also, or alternatively, may include activation of anelectric assembly to operate one or more electrical components used tofacilitate operation of the hydraulic fracturing unit, for example, asdiscussed herein.

The example method 1300, at 1308, further may include activating anauxiliary power assembly. For example, the hydraulic fracturing unit mayinclude an internal combustion engine to supply power to auxiliaryassemblies of the hydraulic fracturing unit, and the internal combustionengine may be started.

The example method 1300, at 1310, also may include initiating a start-upsequence for operation of the gas turbine engine of the hydraulicfracturing unit. For example, starting the gas turbine engine, in someembodiments, may require a sequence of multiple steps to start the gasturbine engine, such as activating a fuel pump and/or opening a fuelvalve to provide a flow of fuel to the combustion section of gas turbineengine and/or initiating rotation of the compressor section of the gasturbine engine via the auxiliary power assembly.

At 1312, the example method 1300 also may include causing an intakeexpansion assembly of an enclosure for the gas turbine engine to moverelative to a main housing from a first or retracted position to asecond or extended position, such that intake ports of the intakeexpansion assembly are positioned to supply air to the gas turbineengine, for example, as described herein. For example, a supervisorycontroller may be configured to communicate one or more signals to anactuator controller (or directly to one or more actuators) to activateone or more actuators to cause the intake expansion assembly to extendfrom the main housing.

At 1314, the example method 1300 may further include determining whetherthe intake expansion assembly has moved to the second or extendedposition. For example, one or more sensors connected to the main housingand/or the intake expansion assembly may be configured to generate oneor more position signals indicative of the position of the intakeexpansion assembly relative to the main housing, for example, asdescribed herein. In some embodiments, the supervisory controller may beconfigured to receive the one or more position signals and determinewhether the intake expansion assembly is in the second position.

If, at 1314, it is determined that the intake expansion assembly is notin the second position, at 1316, the example method 1300 further mayinclude returning to 1312 and attempting to move the intake expansionassembly to the second position and/or to generate a fault signal thatmay notify an operator that the intake expansion assembly is not in thesecond position. For example, a supervisory controller may generate oneor more signals to once again attempt to cause the one or more actuatorsto extend the intake expansion assembly. In some embodiments, thesupervisory controller also, or alternatively, may generate a faultsignal to notify an operator of the failure of the intake expansionassembly to move the second position, which may be displayed on anoutput device, such as a computer display, a smart phone display, acomputer tablet display, a portable computer display, and/or a controlpanel display associated with the hydraulic fracturing unit. In someembodiments, the fault signal may be conveyed visually, audibly, and/ortactilely (e.g., via vibration of a hand-held device).

If, at 1314, it is determined that the intake expansion assembly is inthe second position, at 1318, the example method 1300 may includeactivating one or more fans to draw air into the intake expansionassembly. For example, the supervisory controller may communicate one ormore signals to a fan controller configured to activate the one or morefans in the intake expansion assembly, for example, as describedpreviously herein.

The example method 1300, at 1320, further may include causing the gasturbine engine to begin combustion to drive the hydraulic fracturingpump via, for example, connection through a transmission and driveshaft,as described herein. In some embodiments, the supervisory controller maybe configured to communicate one or more signals to a turbine controllerconfigured to commence operation the gas turbine engine, for example, bycompleting the start-up sequence.

It should be appreciated that subject matter presented herein may beimplemented as a computer process, a computer-controlled apparatus, acomputing system, or an article of manufacture, such as acomputer-readable storage medium. While the subject matter describedherein is presented in the general context of program modules thatexecute on one or more computing devices, those skilled in the art willrecognize that other implementations may be performed in combinationwith other types of program modules. Generally, program modules includeroutines, programs, components, data structures, and other types ofstructures that perform particular tasks or implement particularabstract data types.

Those skilled in the art will also appreciate that aspects of thesubject matter described herein may be practiced on or in conjunctionwith other computer system configurations beyond those described herein,including multiprocessor systems, microprocessor-based or programmableconsumer electronics, minicomputers, mainframe computers, handheldcomputers, mobile telephone devices, tablet computing devices,special-purposed hardware devices, network appliances, and the like.

The controller 80 can include one or more industrial control systems(ICS), such as supervisory control and data acquisition (SCADA) systems,distributed control systems (DCS), and/or programmable logic controllers(PLCs). For example, the controller 80 may include one or moreprocessors, which may operate to perform a variety of functions, as setforth herein. In some examples, the processor(s) may include a centralprocessing unit (CPU), a graphics processing unit (GPU), both CPU andGPU, or other processing units or components. Additionally, at leastsome of the processor(s) may possess local memory, which also may storeprogram modules, program data, and/or one or more operating systems. Theprocessor(s) may interact with, or include, computer-readable media,which may include volatile memory (e.g., RAM), non-volatile memory(e.g., ROM, flash memory, miniature hard drive, memory card, or thelike), or some combination thereof. The computer-readable media may benon-transitory computer-readable media. The computer-readable media maybe configured to store computer-executable instructions, which whenexecuted by a computer, perform various operations associated with theprocessor(s) to perform the operations described herein.

Example embodiments of controllers (e.g., the supervisory controller 186and/or other controllers shown in FIG. 12) may be provided as a computerprogram item including a non-transitory machine-readable storage mediumhaving stored thereon instructions (in compressed or uncompressed form)that may be used to program a computer (or other electronic device) toperform processes or methods described herein. The machine-readablestorage medium may include, but is not limited to, hard drives, floppydiskettes, optical disks, CD-ROMs, DVDs, read-only memories (ROMs),random access memories (RAMs), EPROMs, EEPROMs, flash memory, magneticor optical cards, solid-state memory devices, or other types ofmedia/machine-readable medium suitable for storing electronicinstructions. Further, example embodiments may also be provided as acomputer program item including a transitory machine-readable signal (incompressed or uncompressed form). Examples of machine-readable signals,whether modulated using a carrier or not, include, but are not limitedto, signals that a computer system or machine hosting or running acomputer program can be configured to access, including signalsdownloaded through the Internet or other networks.

Having now described some illustrative embodiments of the disclosure, itshould be apparent to those skilled in the art that the foregoing ismerely illustrative and not limiting, having been presented by way ofexample only. Numerous modifications and other embodiments are withinthe scope of one of ordinary skill in the art and are contemplated asfalling within the scope of the disclosure. In particular, although manyof the examples presented herein involve specific combinations of methodacts or system elements, it should be understood that those acts andthose elements may be combined in other ways to accomplish the sameobjectives. Those skilled in the art should appreciate that theparameters and configurations described herein are exemplary and thatactual parameters and/or configurations will depend on the specificapplication in which the systems and techniques of the invention areused. Those skilled in the art should also recognize or be able toascertain, using no more than routine experimentation, equivalents tothe specific embodiments of the invention. It is, therefore, to beunderstood that the embodiments described herein are presented by way ofexample only and that, within the scope of any appended claims andequivalents thereto, the embodiments of the disclosure may be practicedother than as specifically described.

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/162,022, filed Jan. 29, 2021, titled “SYSTEMS AND METHODS TOENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF A HYDRAULICFRACTURING UNIT”, which is a continuation of U.S. Non-Provisionalapplication Ser. No. 16/946,291, filed Jun. 15, 2020, titled “SYSTEMSAND METHODS TO ENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF AHYDRAULIC FRACTURING UNIT”, now U.S. Pat. No. 10,961,908, issued Mar.30, 2021, which claims the benefit of and priority to U.S. ProvisionalPatent Application No. 62/704,987, filed Jun. 5, 2020, titled “SYSTEMSAND METHODS TO ENHANCE INTAKE AIR FLOW TO A GAS TURBINE ENGINE OF AHYDRAULIC FRACTURING UNIT”, and hereby is incorporated by reference forall purposes as if presented herein in its entirety.

Furthermore, the scope of the present disclosure shall be construed tocover various modifications, combinations, additions, alterations, etc.,above and to the above-described embodiments, which shall be consideredto be within the scope of this disclosure. Accordingly, various featuresand characteristics as discussed herein may be selectively interchangedand applied to other illustrated and non-illustrated embodiment, andnumerous variations, modifications, and additions further can be madethereto without departing from the spirit and scope of the presentinvention as set forth in the appended claims.

What is claimed is:
 1. A gas turbine engine enclosure to increase intakeair flow to a gas turbine engine when positioned in the enclosure, theenclosure comprising: a main housing positioned to receive a gas turbineengine therein and including a main housing wall to connect to aplatform to support the enclosure and the gas turbine engine, the mainhousing wall having a remote end to be positioned remote from theplatform and defining an upper perimeter; an intake expansion assemblyto enhance intake air flow to the gas turbine engine, the intakeexpansion assembly comprising: an intake expansion wall comprising: afirst end defining an expansion perimeter positioned adjacent the upperperimeter of the main housing, a second end opposite the first end, oneor more intake ports positioned to supply intake air to the gas turbineengine when positioned in the enclosure, and a roof panel, and one ormore actuators connected to the main housing and positioned to cause theintake expansion assembly to move relative to the main housing between afirst position preventing air flow through the one or more intake portsand a second position providing air flow through the one or more intakeports to an interior of the enclosure adjacent the gas turbine engine;and one or more filters connected to the intake expansion wall to filterair entering the enclosure via the one or more intake ports.
 2. Theenclosure of claim 1, wherein the intake expansion wall is positionedwith respect to the main housing wall, such that activation of the oneor more actuators causes the intake expansion wall to move between aretracted position preventing air flow through the one or more intakeports to an extended position providing air flow through the one or moreintake ports to an interior of the enclosure.
 3. The enclosure of claim1, further comprising a flexible membrane extending between the mainhousing wall and the intake expansion wall, the flexible membraneproviding a barrier to prevent air from passing between the main housingwall and the intake expansion wall.
 4. The enclosure of claim 3, whereinthe roof panel further is connected to the second end of the intakeexpansion wall, is positioned to enclose the second end of the intakeexpansion wall, and includes one or more filter slots, each of the oneor more filter slots being positioned to receive one or more of the oneor more filters.
 5. The enclosure of claim 4, wherein the one or morefilters comprises a plurality of first filters, and the enclosurefurther comprises a plurality of second filters positioned in the intakeexpansion assembly between the plurality of first filters and an intakeof the gas turbine engine.
 6. The enclosure of claim 1, furthercomprising an expansion base connected to the intake expansion wall, theexpansion base including an expansion base intake port to provide intakeflow between the plurality of intake ports and an intake of the gasturbine engine when positioned in the enclosure.
 7. The enclosure ofclaim 6, further comprising an intake duct connected to the expansionbase and to connect to an intake of the gas turbine engine whenpositioned in the enclosure, the intake duct being flexible to movebetween a retracted position to an extended position.
 8. The enclosureof claim 1, further comprising one or more fans connected to the intakeexpansion assembly to draw air into the enclosure via the one or moreintake ports.
 9. The enclosure of claim 1, wherein the expansionperimeter of the intake expansion wall is positioned to fit inside theupper perimeter of the main housing.
 10. The enclosure of claim 1,wherein the one or more actuators comprise one or more linear actuatorsincluding a first end connected to the main housing wall and a secondend connected to the intake expansion assembly and positioned such thatactivation of the one or more linear actuators causes the intakeexpansion wall to move between a retracted position preventing air flowthrough the plurality of intake ports to an extended position providingair flow through the plurality of intake ports to an interior of theenclosure.
 11. The enclosure of claim 10, wherein the roof panelcomprises a perimeter edge extending laterally beyond an outer surfaceof the intake expansion wall, and the second end of the one or moreactuators is connected to the perimeter edge of the roof panel.
 12. Theenclosure of claim 1, wherein the one or more actuators comprise one ormore rotary actuators including (a) an actuator base connected to one of(i) the main housing or (ii) the intake expansion assembly, and a rotarymember connected to a linkage, the linkage being connected to one of themain housing or the intake expansion assembly, such that activation ofthe one or more rotary actuators causes the intake expansion wall tomove between a retracted position preventing air flow through theplurality of intake ports to an extended position providing air flowthrough the plurality of intake ports to an interior of the enclosure.13. The enclosure of claim 1, further comprising a supervisorycontroller in communication with the one or more actuators andconfigured to cause the one or more actuators to activate and causemovement of the intake expansion wall between the first position and thesecond position.
 14. The enclosure of claim 13, further comprising oneor more sensors configured to be in communication with the supervisorycontroller, the one or more sensors also being connected to one or moreof the main housing or the intake expansion assembly and positioned togenerate one or more position signals indicative of a position of theintake expansion assembly relative to the main housing.
 15. Theenclosure of claim 14, wherein the supervisory controller is configuredto be in communication with a turbine controller configured to initiateoperation of the gas turbine engine when positioned in the enclosure,and wherein the supervisory controller is configured to: receive the oneor more position signals from the one or more sensors; determine theposition of the intake expansion assembly relative to the main housingusing said position signals; and based at least in part on the position,prevent initiation of operation of the gas turbine engine.
 16. Theenclosure of claim 1, further comprising: one or more fans connected tothe intake expansion assembly to draw air into the enclosure via the oneor more intake ports, the one or more fans configured to be in incommunication with a supervisory controller configured to activate theone or more fans when the intake expansion wall is in the secondposition.
 17. The enclosure of claim 1, further comprising cooling coilsconnected to an interior of the intake expansion assembly and positionedto cool air prior to entering an intake of the gas turbine engine whenpositioned in the enclosure.
 18. The enclosure of claim 1, furthercomprising an interior partition connected to an interior of the intakeexpansion assembly and positioned to provide a first portion of theinterior of the intake expansion assembly and a second portion of theinterior of the intake expansion assembly.
 19. The enclosure of claim18, further comprising: a first fan connected to the interior of theintake expansion assembly and positioned to pull air into the firstportion of the interior of the intake expansion assembly; and a secondfan connected to the interior of the intake expansion assembly andpositioned to pull air into the second portion of the interior of theintake expansion assembly.
 20. The enclosure of claim 1, furthercomprising one or more seal material segments on an interior side of theroof panel and positioned to provide a seal between one or morecomponents positioned in an interior of the intake expansion assemblyand the interior side of the roof panel.
 21. A power assembly to providepower to a hydraulic fracturing unit, the hydraulic fracturing unitincluding a driveshaft to connect to a hydraulic fracturing pump, atransmission to connect to a gas turbine engine for driving thedriveshaft and thereby the hydraulic fracturing pump, the power assemblycomprising: an enclosure positioned to be supported by a platform; and agas turbine engine positioned on the platform, in the enclosure, and tobe connected to the hydraulic fracturing pump via the transmission andthe driveshaft; the enclosure comprising: a main housing including amain housing wall to connect to the platform to support the enclosure;an intake expansion assembly to enhance intake air flow to the gasturbine engine, the intake expansion assembly comprising: an intakeexpansion wall including: a first end defining an expansion perimeterpositioned to fit one of inside or outside the upper perimeter of themain housing; a second end opposite the first end, a roof panelconnected to the second end of the intake expansion wall; and one ormore intake ports positioned to supply intake air to the gas turbineengine positioned in the enclosure; and one or more actuators connectedto the main housing and the intake expansion assembly and positioned tocause the intake expansion assembly to move relative to the main housingbetween a first position preventing air flow through the plurality ofintake ports and a second position providing air flow through the one ormore intake ports to an interior of the enclosure.
 22. The powerassembly of claim 21, wherein: the gas turbine engine includes an intakeand an exhaust duct; the main housing wall includes an exhaust duct portthrough which exhaust from operation of the gas turbine engine passesvia the exhaust duct; and the intake expansion wall being devoid of anintake port adjacent the exhaust duct port to prevent exhaust fromentering an intake of the gas turbine engine during operation.
 23. Thepower assembly of claim 21, further comprising one or more filtersconnected to the intake expansion wall to filter air entering theenclosure via the plurality of intake ports, wherein the one or morefilters comprises a plurality of first filters, and the enclosurefurther comprises a plurality of second filters positioned in the intakeexpansion assembly between the plurality of first filters and an intakeof the gas turbine engine.
 24. The power assembly of claim 22, whereinthe gas turbine engine includes an intake, and the intake expansionassembly further comprises an expansion base connected to the intakeexpansion wall, the expansion base including one or more expansion baseintake ports providing intake flow between the one or more of theexpansion base intake ports and an intake of the gas turbine engine whenthe intake expansion wall is in the second position.
 25. The powerassembly of claim 24, further comprising an intake duct connected to theexpansion base and the intake of the gas turbine engine, the intake ductbeing flexible to move from an at least partially retracted position toan extended position when the intake expansion wall moves from the firstposition to the second position.
 26. A power assembly to provide powerto a hydraulic fracturing unit, the hydraulic fracturing unit includinga driveshaft to connect to a hydraulic fracturing pump, a transmissionto connect to a gas turbine engine for driving the driveshaft andthereby the hydraulic fracturing pump, the power assembly comprising: aplatform; an enclosure positioned to be supported by the platform; a gasturbine engine positioned to be supported by the platform, in theenclosure, and to be connected to the hydraulic fracturing pump via thetransmission and the driveshaft, the enclosure comprising: a mainhousing including a main housing wall connected to the platform; anintake expansion assembly to enhance intake air flow to the gas turbineengine, the intake expansion assembly comprising: an intake expansionwall including: one or more intake ports positioned to supply intake airto the gas turbine engine positioned in the enclosure, a first enddefining an expansion perimeter positioned to fit one of inside oroutside the upper perimeter of the main housing, a second end oppositethe first end, and a roof panel; one or more actuators connected to themain housing and the intake expansion assembly and positioned to causethe intake expansion assembly to move relative to the main housingbetween a first position preventing air flow through the plurality ofintake ports and a second position providing air flow through theplurality of intake ports to an interior of the enclosure; and acontroller in communication with the one or more actuators andconfigured to cause the one or more actuators to activate and causemovement of the intake expansion wall between the first position and thesecond position.
 27. The power assembly of claim 26, further comprisingone or more sensors in communication with the controller and connectedto one or more of the main housing or the intake expansion assembly andpositioned to generate one or more position signals indicative of aposition of the intake expansion assembly relative to the main housing.28. The power assembly of claim 27, wherein the controller comprises asupervisory controller and is configured to be in communication with aturbine controller configured to initiate operation of the gas turbineengine, and wherein the supervisory controller also is configured to:receive the one or more position signals from the one or more sensors;determine the position of the intake expansion assembly relative to themain housing using the position signals; and based at least in part onthe position, prevent initiation of operation of the gas turbine engine.29. The power assembly of claim 27, wherein the roof panel is connectedto the second end of the intake expansion wall and enclosing the secondend of the intake expansion wall, and the roof panel includes aperimeter edge extending laterally beyond an outer surface of the intakeexpansion wall, and wherein the one or more actuators are connected tothe perimeter edge of the roof panel.
 30. The power assembly of claim26, further comprising one or more filters connected to the intakeexpansion wall to filter air entering the enclosure via the plurality ofintake ports.